Laminating thin strengthened glass to curved molded plastic surface for decorative and display cover application

ABSTRACT

A process comprises cold-forming a flat glass substrate into a non-planar shape using a die. The cold-formed glass substrate is bonded to a non-planar rigid support structure at a plurality of non-planar points using the die. Bonding methods include injection molding the non-planar rigid support structure, and direct bonding. An article is also provided, comprising a cold-formed glass substrate having opposing major surfaces and a curved shape, the opposing major surfaces comprising a surface stress that differ from one another. The cold-formed glass substrate is attached to a rigid support structure having the curved shape. The cold-formed glass substrate includes an open region not in direct contact with the non-planar rigid support structure, and the open region has a curved shape maintained by the non-planar rigid support structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application and claims the benefit ofpriority under 35 U.S.C. § 120 of U.S. application Ser. No. 17/007,757filed Aug. 31, 2020, which in turn, claims the benefit of priority under35 U.S.C. § 120 of U.S. patent application Ser. No. 16/312,797 filedDec. 21, 2018, which claims the benefit of priority under 35 U.S.C. §371 of International Patent Application Serial No. PCT/US2017/039752,filed on Jun. 28, 2017 which in turn, claims the benefit of priorityunder 35 U.S.C. § 119 of U.S. Provisional Application Ser. No.62/444,470 filed on Jan. 10, 2017 and U.S. Provisional Application Ser.No. 62/355,542 filed on Jun. 28, 2016, the contents of which are reliedupon and incorporated herein by reference in their entirety.

BACKGROUND

The present disclosure relates to curved cold-formed glass substrates,articles including such glass substrates, and related processes.

Curved glass substrates are desirable in many contexts. One such contextis for use as a cover glass for a curved display, which may beincorporated into an appliance, an architectural element (e.g., wall,window, modular furniture, shower door, mirrors etc.), a vehicle (e.g.,automobiles, aircraft, sea craft and the like). Existing methods offorming such curved glass substrates, such as thermal forming, havedrawbacks including optical distortion and surface marking. Accordingly,there is a need for curved glass substrates that do not exhibit theoptical distortion and surface marking typically found inthermally-formed curved glass substrates.

BRIEF SUMMARY

The present disclosure is directed to articles comprising cold-formedglass substrates bonded to a non-planar rigid support structure, andmethods of making such articles.

In some embodiments, a process comprises cold-forming a flat glasssubstrate into a non-planar shape using a die. In one or moreembodiments, the cold-formed glass substrate is bonded to a non-planarrigid support structure at a plurality of non-planar points using thedie.

In some embodiments, a process comprises cold-forming a flat glasssubstrate into a non-planar shape using an injection-molding die. Insome embodiments, bonding is accomplished by injection molding thenon-planar rigid support structure onto the cold-formed glass substratewhile the die holds the cold-formed glass substrate in the non-planarshape.

In some embodiments, the process further comprises, after bonding,applying an adhesive to an edge of an interface between the cold-formedglass substrate and the non-planar rigid support structure.

In some embodiments, a process comprises cold-forming a glass substrateinto a non-planar shape. In some embodiments, bonding is accomplished byusing the die to directly bond the cold-formed glass substrate onto anon-planar rigid support structure. In one or more embodiments, thenon-planar rigid support structure is formed prior to the bonding.

In some embodiments, the non-planar rigid support structure is placedinto a recess in the die prior to bonding.

In some embodiments, the process further comprises applying a coating orsurface treatment to a surface of the flat glass substrate prior tocold-forming. The coating may be an ink coating, an antireflectivecoating, an antiglare coating and/or any other suitable coating. Thesurface treatment may include an antiglare surface, a haptic surfacethat provides tactile feedback, and the like.

In some embodiments, the cold-formed glass substrate, after bonding tothe non-planar rigid support structure, includes an open region not indirect contact with the non-planar rigid support structure, the openregion having a curved shape maintained by the non-planar rigid supportstructure. A display may be attached to at least one of the cold-formedglass substrate and the non-planar rigid support structure, such thatthe display is visible through the open region of the cold-formed glasssubstrate.

In some embodiments, during and after cold-forming, the temperature ofthe glass substrate does not exceed 800° F.

In some embodiments, the flat glass substrate comprises a strengthenedglass. The strengthened glass may include a chemically strengthenedglass, a thermally strengthened glass, a mechanically strengthened glassor a glass that has been strengthened using any one or more of chemicalstrengthening, thermal strengthening and mechanical strengthening.

In some embodiments, the cold-formed glass substrate has opposing majorsurfaces, and the non-planar rigid support structure is bonded to onlyone of the major surfaces.

In some embodiments, an article is formed by any of the processesdescribed herein.

In some embodiments, an article comprises a cold-formed glass substratehaving opposing major surfaces and a curved shape, the opposing majorsurfaces comprising a surface stress that differ from one another. Inone or more embodiments, the cold-formed glass substrate is attached toa rigid support structure having the curved shape. In one or moreembodiments, the cold-formed glass substrate includes an open region notin direct contact with the non-planar rigid support structure, and theopen region has a curved shape maintained by the non-planar rigidsupport structure.

In some embodiments, an article comprises a non-planar rigid supportstructure having a developable surface. A cold-formed glass substrate isbonded to the non-planar rigid support structure. The cold formed glasssubstrate has the developable surface.

In some embodiments, a display is attached to at least one of thecold-formed glass substrate and the non-planar rigid support structure.The display is visible through the open region of the cold-formed glasssubstrate. In one or more embodiments, the cold-formed glass substratemay be free of open regions (i.e., the glass substrate may be acontinuous sheet) and the display may be visible through the cold-formedglass substrate.

In some embodiments, the cold-formed glass substrate comprises any oneor both a coating and a surface treatment on a major surface thereof.The coating may be an ink coating, an antireflective coating, anantiglare coating and/or any other suitable coating. The surfacetreatment may include an antiglare surface, a haptic surface thatprovides tactile feedback, and the like.

In some embodiments, the cold-formed glass substrate is a strengthenedglass substrate. The strengthened glass may include a chemicallystrengthened glass, a thermally strengthened glass, a mechanicallystrengthened glass or a glass that has been strengthened using any oneor more of chemical strengthening, thermal strengthening and mechanicalstrengthening.

In some embodiments, the non-planar rigid support structure is bonded toonly one of the major surfaces.

In some embodiments, the cold formed glass substrate has a developablesurface.

The embodiments of the preceding paragraphs may be combined in anypermutation.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, which are incorporated herein, form part ofthe specification and illustrate embodiments of the present disclosure.Together with the description, the figures further serve to explain theprinciples of and to enable a person skilled in the relevant art(s) tomake and use the disclosed embodiments. These figures are intended to beillustrative, not limiting. Although the disclosure is generallydescribed in the context of these embodiments, it should be understoodthat it is not intended to limit the scope of the disclosure to theseparticular embodiments. In the drawings, like reference numbers indicateidentical or functionally similar elements.

FIG. 1 illustrates an injection mold die designed with a specificdesired curved shape, and a flat glass substrate.

FIG. 2 illustrates the die of FIG. 1 cold-forming the glass substrateinto a non-planar shape.

FIG. 3 illustrates the die of FIG. 2 after material has beeninjection-molded into recesses in the die to form a non-planar rigidsupport structure bonded to the back of the cold-formed glass substrate.

FIG. 4 illustrates the die of FIG. 3 and the resultant article after thedie retracts. The resultant article is a cold-formed glass substratebonded to a non-planar rigid support structure. The cold-formed coverglass substrate retains design curvature because of the rigidity of thestructural backside support molded onto the back side of the cold-formedcover glass substrate.

FIG. 5 shows the cold-formed glass substrate bonded to a non-planarrigid support structure of FIG. 4 , with additional adhesive.

FIG. 6 shows a perspective view of a cold-formed glass substrate bondedto a non-planar rigid support structure.

FIG. 7 shows a top view of a cold-formed glass substrate bonded to anon-planar rigid support structure. The curvature is not visible due tothe angle of the view.

FIG. 8 illustrates a direct-bonding die designed with a specific desiredcurved shape, and a flat glass substrate. A non-planar rigid supportstructure has been inserted into recesses in the die.

FIG. 9 illustrates the die of FIG. 8 cold-forming the glass substrateinto a non-planar shape and bonding the non-planar rigid supportstructure to the cold-formed glass substrate.

FIG. 10 illustrates the die of FIG. 9 and the resultant article afterthe die retracts. The resultant article is a cold-formed glass substratebonded to a non-planar rigid support structure. The cold-formed coverglass substrate retains design curvature because of the rigidity of thestructural backside support bonded to the back side of the cover glass.

FIG. 11 shows the cold-formed glass substrate bonded to a non-planarrigid support structure of FIG. 10 , with additional adhesive.

FIG. 12 shows a process flowchart corresponding to the processillustrated in FIGS. 1 to 5 .

FIG. 13 shows a process flowchart corresponding to the processillustrated in FIGS. 8 to 10 .

FIG. 14 illustrates a die having ridges that precisely position a glasssubstrate.

FIG. 15 illustrates an automotive interior display comprising acold-formed glass substrate bonded to a non-planar rigid supportstructure.

FIG. 16 shows a top view of a cold-formed glass substrate bonded to anon-planar rigid support structure, having a display bonded to thecold-formed glass substrate. The curvature is not visible due to theangle of the view.

FIG. 17 shows a side view of a glass substrate being applied to a rigidsupport structure having a developable surface using a single roller.

DETAILED DESCRIPTION

Vehicle manufactures are creating interiors that better connect, protectand safely inform today's drivers and passengers. As the industry movestowards autonomous driving, there is a need for creating large formatappealing displays. There is already a trend towards larger displaysincluding touch functionality in the new models from several OEMs. Suchtrends are also immerging in appliances, architectural elements (e.g.,wall, window, modular furniture, shower door, mirrors etc.), and othervehicles (e.g., aircraft, seacraft and the like). However, most of thesedisplays consist of two dimensional plastic cover lens.

Due to these emerging trends in the automotive interior industry andrelated industries, there is a need to develop a low cost technology tomake three-dimensional transparent surfaces. Strengthened glassmaterials, such as chemically strengthened, thermally strengthenedand/or mechanically strengthened glass materials are particularlydesirable for use as such surfaces, particularly where the glasssubstrate is used as a curved cover glass for a display.

However, many methods for forming curved glass surfaces involvesubjecting glass substrates to thermal forming processes (includingthermal forming processes that include heating a glass substrate to atemperature above the transition temperature of the glass). Suchprocesses can be energy intensive due to the high temperatures involvedand such processes add significant cost to the product. Furthermore,thermal forming processes may cause strength degradation or may damageany coatings present on the glass substrate, such as antireflective (AR)coatings or ink coatings. Moreover, thermal forming processes may impartundesirable characteristics onto the glass itself, such as distortionand marking.

A planar glass substrate may be “cold-formed” to have a curved orthree-dimensional shape. As used herein, “cold-forming” refers tobending the glass substrate at temperatures below the glass transitiontemperature of the glass. In some embodiments, cold-forming occurs attemperatures below 800° F. A cold-formed glass substrate has opposingmajor surfaces and a curved shape. The opposing major surfaces exhibit asurface stress that differs from one another that are created duringcold-forming. The stresses include surface compressive stressesgenerated by the cold-forming process. These stresses are not thermallyrelaxed because the glass substrate is maintained at temperatures wellbelow the glass transition temperature.

In some embodiments, a cold-formed glass substrate forms a “developable”surface. A developable surface has a surface with zero Gaussiancurvature. In one or more embodiments, the developable surface meansthat all points of the cold-formed glass substrate surface have aGaussian curvature (GC) that is equal to zero (wherein GC is equal toKmax*Kmin, wherein Kmax and Kmin are principal curvatures defined asKmax=1/R′ and Kmin=1/R″), and wherein one of Kmax and Kmin is non-zero.R′ is the maximum radius of curvature and R″ is the minimum radius ofcurvature. In one or more embodiments, the surface of the cold-formedglass substrate that can be flattened into a plane without stretching orcompressing within the plane of the surface.

Examples of developable surfaces include cones, cylinders, oloids,tangent developable surfaces, and portions thereof. A surface thatprojects onto a single curved line is a developable surface.

In some embodiments, the article may include a glass substrate that isprovided as a sheet and that is strengthened (prior to being shaped intosome embodiments of the article described herein). For example, theglass substrate may be strengthened by any one or more of thermalstrengthening, chemical strengthening, mechanical strengthening or by acombination thereof. In some embodiments, strengthened glass substratehave a compressive stress (CS) layer extending from a surface of thesubstrate thereof to a compressive stress depth (or depth of compressivestress layer or DOL). The depth of compression is the depth at whichcompressive stress switches to tensile stress. The region within theglass substrate exhibiting a tensile stress is often referred to as acentral tension or CT layer.

As used herein, “thermally strengthened” refers to glass substrates thatare heat treated to improve the strength of the substrate. Inthermally-strengthened glass substrates, the CS layer is formed byheating the substrate to an elevated temperature above the glasstransition temperature (i.e., near or approaching the glass softeningpoint), and then cooling the glass surface regions more rapidly than theinner regions of the glass. The differential cooling rates between thesurface regions and the inner regions generates a residual CS layer atthe surfaces.

Factors that impact the degree of surface compression generated bythermal strengthening processes include the air-quench temperature,volume, and other variables that create a surface compression of atleast 10,000 pounds per square inch (psi). In chemically strengthenedglass substrates, the replacement of smaller ions by larger ions at atemperature below that at which the glass network can relax produces adistribution of ions across the surface of the glass that results in astress profile. The larger volume of the incoming ion produces the CSlayer extending from a surface and the CT layer in the center of theglass. Chemical strengthening may be achieved by an ion exchange processwhich includes immersion of a glass substrate into a molten salt bathfor a predetermined period of time to allow ions at or near thesurface(s) of the glass substrate to be exchanged for larger metal ionsfrom the salt bath. In some embodiments, the temperature of the moltensalt bath is from about 375° C. to about 450° C. and the predeterminedtime period is in the range from about four to about eight hours. In oneexample, sodium ions in a glass substrate are replaced by potassium ionsfrom the molten bath, such as a potassium nitrate salt bath, thoughother alkali metal ions having larger atomic radii, such as rubidium orcesium, can replace smaller alkali metal ions in the glass. In anotherexample, lithium ions in a glass substrate are replaced by potassiumand/or sodium ions from the molten bath that may include potassiumnitrate, sodium nitrate or a combination thereof, although other alkalimetal ions having larger atomic radii, such as rubidium or cesium, canreplace smaller alkali metal ions in the glass. In some embodiments,smaller alkali metal ions in the glass substrate can be replaced by Ag+ions. Similarly, other alkali metal salts such as, but not limited to,sulfates, phosphates, halides, and the like may be used in the ionexchange process. The glass substrate may be immersed in a single bathor in multiple and successive baths which may have the same or differentcomposition and/or temperature from one another. In some embodiments,the immersion in such multiple baths may be for different periods oftime from one another.

In mechanically-strengthened glass substrates, the CS layer is generatedby a mismatch of the coefficient of thermal expansion between portionsof the glass substrate.

In strengthened glass substrates, the DOL is related to the CT value bythe following approximate relationship (Equation 1)

$\begin{matrix}{{CT} \cong \frac{{CS} \times {DOL}}{{thickness} - {2 \times {DOL}}}} & (1)\end{matrix}$

where thickness is the total thickness of the strengthened glasssubstrate and DOL depth of layer (DOL) is the depth of the compressivestress. Unless otherwise specified, central tension CT and compressivestress CS are expressed herein in megaPascals (MPa), whereas thicknessand depth of layer DOL are expressed in millimeters or microns. Unlessotherwise described, the CS value is the value measured at the surfaceand the CT value is the tensile stress value (as determined by Equation1).

In some embodiments, a strengthened glass substrate can have a surfaceCS of 300 MPa or greater, e.g., 400 MPa or greater, 450 MPa or greater,500 MPa or greater, 550 MPa or greater, 600 MPa or greater, 650 MPa orgreater, 700 MPa or greater, 750 MPa or greater or 800 MPa or greater.In some embodiments, the surface CS is the maximum CS in the glasssubstrate. The strengthened glass substrate may have a DOL of 15micrometers or greater, 20 micrometers or greater (e.g., 25, 30, 35, 40,45, 50 micrometers or greater) and/or a maximum CT value of 10 MPa orgreater, 20 MPa or greater, 30 MPa or greater, 40 MPa or greater (e.g.,42 MPa, 45 MPa, or 50 MPa or greater) but less than 100 MPa (e.g., 95,90, 85, 80, 75, 70, 65, 60, 55 MPa or less). In one or more specificembodiments, the strengthened glass substrate has one or more of thefollowing: a surface CS greater than 500 MPa, a DOL greater than 15micrometers, and a maximum CT of greater than 18 MPa.

The CS and DOL may be determined by surface stress meter such as thecommercially available FSM-6000 instrument, manufactured by OriharaIndustrial, Co., Ltd. (Tokyo, Japan). Surface stress measurements relyupon the accurate measurement of the stress optical coefficient (SOC),which is related to the birefringence of the glass. SOC in turn ismeasured by those methods that are known in the art, such as fiber andfour point bend methods, both of which are described in ASTM standardC770-98 (2013), entitled “Standard Test Method for Measurement of GlassStress-Optical Coefficient,” the contents of which are incorporatedherein by reference in their entirety, and a bulk cylinder method.

The materials for the glass substrates may be varied. The glasssubstrates used to form the articles described herein can be amorphousor crystalline. In this regard, the use of the term “glass” is generaland is intended to encompass more than strictly amorphous materials.Amorphous glass substrates according to some embodiments can be selectedfrom soda lime glass, alkali aluminosilicate glass, alkali containingborosilicate glass and alkali aluminoborosilicate glass. Examples ofcrystalline glass substrates can include glass-ceramics, sapphire orspinel. Examples of glass-ceramics include Li2O-Al2O3-SiO2 system (i.e.LAS-System) glass ceramics, MgO-Al2O3-SiO2 System (i.e. MAS-System)glass ceramics, glass ceramics including crystalline phases of any oneor more of mullite, spinel, α-quartz, β-quartz solid solution, petalite,lithium dissilicate, β-spodumene, nepheline, and alumina.

Glass substrates may be provided using a variety of different processes.For example, exemplary glass substrate forming methods include floatglass processes and down-draw processes such as fusion draw and slotdraw. A glass substrate prepared by a float glass process may becharacterized by smooth surfaces and uniform thickness is made byfloating molten glass on a bed of molten metal, typically tin. In anexample process, molten glass that is fed onto the surface of the moltentin bed forms a floating glass ribbon. As the glass ribbon flows alongthe tin bath, the temperature is gradually decreased until the glassribbon solidifies into a solid glass substrate that can be lifted fromthe tin onto rollers. Once off the bath, the glass substrate can becooled further and annealed to reduce internal stress.

Down-draw processes produce glass substrate having a uniform thicknessthat possess relatively pristine surfaces. Because the average flexuralstrength of the glass substrate is controlled by the amount and size ofsurface flaws, a pristine surface that has had minimal contact has ahigher initial strength. Down-drawn glass substrate may be drawn into asheet having a thickness of less than about 2 millimeters. In addition,down drawn glass substrate have a very flat, smooth surface that can beused in its final application without costly grinding and polishing.

The fusion draw process, for example, uses a drawing tank that has achannel for accepting molten glass raw material. The channel has weirsthat are open at the top along the length of the channel on both sidesof the channel. When the channel fills with molten material, the moltenglass overflows the weirs. Due to gravity, the molten glass flows downthe outside surfaces of the drawing tank as two flowing glass films.These outside surfaces of the drawing tank extend down and inwardly sothat they join at an edge below the drawing tank. The two flowing glassfilms join at this edge to fuse and form a single flowing sheet ofglass. The fusion draw method offers the advantage that, because the twoglass films flowing over the channel fuse together, neither of theoutside surfaces of the resulting sheet of glass comes in contact withany part of the apparatus. Thus, the surface properties of the fusiondrawn sheet of glass are not affected by such contact.

The slot draw process is distinct from the fusion draw method. In slowdraw processes, the molten raw material glass is provided to a drawingtank. The bottom of the drawing tank has an open slot with a nozzle thatextends the length of the slot. The molten glass flows through theslot/nozzle and is drawn downward as a continuous sheet and into anannealing region.

Exemplary compositions for use in the glass substrate will now bedescribed. One example glass composition comprises SiO2, B2O3 and Na2O,where (SiO2+B2O3)≥66 mol. %, and Na2O≥9 mol. %. Suitable glasscompositions, in some embodiments, further comprise at least one of K2O,MgO, and CaO. In some embodiments, the glass compositions can comprise61-75 mol. % SiO2; 7-15 mol. % Al₂O₃; 0-12 mol. % B2O3; 9-21 mol. %Na2O; 0-4 mol. % K2O; 0-7 mol. % MgO; and 0-3 mol. % CaO.

A further example glass composition comprises: 60-70 mol. % SiO2; 6-14mol. % Al2O3; 0-15 mol. % B2O3; 0-15 mol. % Li2O; 0-20 mol. % Na2O; 0-10mol. % K2O; 0-8 mol. % MgO; 0-10 mol. % CaO; 0-5 mol. % ZrO2; 0-1 mol. %SnO2; 0-1 mol. % CeO2; less than 50 ppm As2O3; and less than 50 ppmSb2O3; where 12 mol. %≤(Li2O+Na2O+K2O)≤20 mol. % and 0 mol.%≤(MgO+CaO)≤10 mol. %.

A still further example glass composition comprises: 63.5-66.5 mol. %SiO2; 8-12 mol. % Al2O3; 0-3 mol. % B2O3; 0-5 mol. % Li2O; 8-18 mol. %Na2O; 0-5 mol. % K2O; 1-7 mol. % MgO; 0-2.5 mol. % CaO; 0-3 mol. % ZrO2;0.05-0.25 mol. % SnO2; 0.05-0.5 mol. % CeO2; less than 50 ppm As2O3; andless than 50 ppm Sb2O3; where 14 mol. %≤(Li2O+Na2O+K2O)≤18 mol. % and 2mol. %≤(MgO+CaO)≤7 mol. %.

In some embodiments, an alkali aluminosilicate glass compositioncomprises alumina, at least one alkali metal and, in some embodiments,greater than 50 mol. % SiO2, in some embodiments at least 58 mol. %SiO2, and in some embodiments at least 60 mol. % SiO2, wherein the ratio((Al2O3+B2O3)/Σ modifiers)>1, where in the ratio the components areexpressed in mol. % and the modifiers are alkali metal oxides. Thisglass composition, in some embodiments, comprises: 58-72 mol. % SiO2;9-17 mol. % Al2O3; 2-12 mol. % B2O3; 8-16 mol. % Na2O; and 0-4 mol. %K2O, wherein the ratio((Al2O3+B2O3)/Σmodifiers)>1.

In some embodiments, the glass substrate may include an alkalialuminosilicate glass composition comprising: 64-68 mol. % SiO2; 12-16mol. % Na2O; 8-12 mol. % Al₂O₃; 0-3 mol. % B2O3; 2-5 mol. % K2O; 4-6mol. % MgO; and 0-5 mol. % CaO, wherein: 66 mol. %□SiO2+B2O3+CaO□69 mol.%; Na2O+K2O+B2O3+MgO+CaO+SrO>10 mol. %; 5 mol. %□MgO+CaO+SrO□8 mol. %;(Na2O+B2O3)□Al2O3□2 mol. %; 2 mol. %□Na2O□Al2O3□6 mol. %; and 4 mol.%□(Na2O+K2O) □Al2O3□10 mol. %.

In some embodiments, the glass substrate may comprise an alkalialuminosilicate glass composition comprising: 2 mol % or more of Al2O3and/or ZrO2, or 4 mol % or more of Al2O3 and/or ZrO2.

In some embodiments, the compositions used for a glass substrate may bebatched with 0-2 mol. % of at least one fining agent selected from agroup that includes Na2SO4, NaCl, NaF, NaBr, K2SO4, KCl, KF, KBr, andSnO2.

The articles may be a single sheet of glass or a laminate. According tosome embodiments, a laminate refers to opposing glass substrates, suchas the glass substrates described herein. In some embodiments, the glasssubstrates may be separated by an interlayer, for example, poly(vinylbutyral) (PVB), ethylenevinylacetate (EVA), polyvinyl chloride (PVC),ionomers, and thermoplastic polyurethane (TPU). A glass substrateforming part of a laminate can be strengthened (chemically, thermally,and/or mechanically) as described above. Thus, laminates according tosome embodiments comprise at least two glass substrates bonded togetherby an interlayer in which a first glass substrate defines a first plyand a second glass substrate defines a second ply. The second ply mayface the user of a display (i.e., the interior of a vehicle, the userfacing panel of an appliance or the user facing surface of anarchitectural element), while the first play may face the oppositedirection. In vehicle applications such as automotive glazings, thefirst ply is exposed to a vehicle or automobile interior and the secondply faces an outside environment of the automobile. In some embodiments,the user interface may be from the interior, from the exterior or fromboth the interior and the exterior of the laminate, when used inautomotive glazings. In vehicle applications such as automotiveinteriors, the second ply is unexposed and placed on an underlyingsupport (e.g., a display, dashboard, center console, instrument panel,seat back, seat front, floor board, door panel, pillar, arm rest etc.),and the first ply is exposed to the vehicle or automobile interior andthus the user. In architectural applications, the second ply is exposedto a building, room, or furniture interior and the first ply faces anoutside environment of the building, room or furniture.

Although various specific glasses are described herein, in someembodiments, any cold-formable glass may be used.

Some embodiments of the articles disclosed herein are useful inautomobile interiors because such articles provide a curved covercompatible with curved displays. To be compatible with a curved display,a cover should match the shape of the curved display closely to insureoptimal fit and enable a high quality viewing. It is also desirable toprovide a cover that is high optical quality and cost effective. Thermalforming a cover to the precise shape presents challenges in attainingthat desired shape. In addition, when glass is used, it is a challengeto minimize the downside effects of heating the cover to its softeningpoint (e.g., distortion, and marking). The concept of cold-formingaddresses these issues and permits the use of glass but creates newchallenges in providing a sufficient support to maintain the cold-formshape and provide rigidity. The ability to cold-form a thin glasssubstrate to the prescribed shape presents the opportunity for a highquality, cost effective solution.

Moreover, the articles described herein are also compatible withcoatings and surface treatments that are often desirable. Examples ofsuch coatings include anti-reflective (AR), antiglare (AG) anddecorative and/or functional coatings. Examples of such surfacetreatments include AG surfaces, a haptic surface that provides tactilefeedback, and the like. AR and AG coatings and AG surfaces may improvedisplay visibility in a variety of challenging ambient lightingconditions. High-quality multi-layer AR coating processes are typicallyapplied utilizing vapor deposition or sputter coating techniques. Thesetechniques are usually limited to deposition on flat surfaces due to thenature of the process. Providing these coatings on a curved threedimensional surface is challenging and further adds to the cost of theprocess. Decorative ink coatings can be applied to a variety ofshaped/curved surfaces, however the process to apply these coating toflat surfaces are simpler, better established, and more cost effective.Further, surface treatments (typically formed by etching treatments) arealso typically applied to flat surfaces.

In one or more embodiments, the article includes a cold-formed glasssubstrate with a non-planar shape and a first major surface and anopposing second major surface and a non-planar rigid support structurebonded to the first major surface at one or more non-planar points. Insome embodiments, the non-planar rigid support structure is bonded tothe first major surface at a plurality of non-planar points.

In some embodiments, the glass substrate is cold-formed and exhibits asurface compressive stress on the first and second major surfaces thatdiffer from one another at, near or adjacent the one or more non-planarpoints. As illustrated in FIG. 4 , first and second major surfaces 121and 122 are in tension or compression depending on the direction ofcurvature. First major surface 121 at a first position 121A adjacent thenon-planar rigid support structure 130 is in tension, while second majorsurface 122 at a second position 122A adjacent the same non-planar rigidsupport structure 130 is in compression. Accordingly, the second majorsurface 122 at the second position 122A exhibits a greater surfacecompressive stress than first major surface 121 at a first position121A. This is asymmetrical surface compressive stress is exhibited evenwhen the glass substrate 120 is strengthened as described herein andexhibits a surface compressive stress prior to being cold-formed. In oneor more embodiments, first position 121A and the second position 122A ofthe respective first and second major surfaces 121, 122 are adjacent thesame non-planar rigid support such that either one or both the firstposition and the second positions is located at a distance of 5centimeters or less from the non-planar rigid support structure 130. Inone or more embodiments, either one or both the first position and thesecond position are located at a distance of 4 centimeters or less, 3centimeters or less, 3 centimeters or less, 2 centimeters or less, 1centimeter or less or 0.5 centimeter or less from the non-planar rigidsupport structure 130. The distances of the first and second positionsrelative to the non-planar rigid support structure 130 are measured fromthe center 131 of the non-planar rigid support structure 130 to therespective first and second positions. In some embodiments, the firstposition 121A and the second position 122A are located directly oppositefrom one another and exhibit the asymmetric surface compressive stressdescribed herein, as illustrated in FIG. 5

In one or more embodiments, the non-planar rigid support structure isinjection molded onto the cold-formed glass substrate while thecold-formed glass comprises the non-planar shape. In some embodiments,either one or both the first major surface and the second major surfaceof the glass substrate may include a coating or surface treatment (e.g.,the coating may include an ink coating and/or an antireflective coating,the surface treatment may include an antiglare treatment). In someinstances, the article may include an edge adhesive applied to an edgeof an interface between the cold-formed glass substrate and thenon-planar rigid support structure. The edge interface may be betweenone or more minor surface(s) of the cold-formed glass substrate and thenon-planar rigid support structure. The minor surface(s) of thecold-formed glass substrate is orthogonal to the first and second majorsurfaces. In one or more embodiments, the edge interface may besubstantially free of an adhesive or other material such that one ormore minor surfaces are exposed.

In some instances, the glass substrate includes an open region not indirect contact with the non-planar rigid support structure, and the openregion has a curved shape maintained by the non-planar rigid supportstructure. In some instances, the article includes a display disposed onat least one of the glass substrate and the non-planar rigid supportstructure, wherein the display is visible through the cold-formed glasssubstrate. In some instances, the display may be attached to at leastone of the glass substrate and the non-planar rigid support structure.

In one or more embodiments, the article includes a glass substratehaving opposing major surfaces and a curved shape that is attached to arigid support structure having the curved shape, wherein the glasssubstrate includes an open region not in direct contact with thenon-planar rigid support structure, and the open region has a curvedshape maintained by the non-planar rigid support structure. In suchembodiments, the glass substrate exhibits a surface compressive stresson the first and second major surfaces that differ from one another asdescribed herein. In one or more embodiments, the article may include adisplay that is attached to at least one of the cold formed glasssubstrate and the non-planar rigid support structure, wherein thedisplay is visible through the open region of the glass substrate. Insome embodiments, the glass substrate comprises a coating disposed oneither one or both the first major surface or the second major surface.The coating may include an ink or an anti-reflective coating. The glasssubstrate may be strengthened glass substrate. In some instances, onlyone of the major surfaces is bonded to the non-planar rigid support.

In some embodiments, a cold-formed glass substrate has a developablesurface. A complex developable surface refers to a combination of two ormore developable surfaces such as cones, cylinders, oloids, planes andtangent developable surfaces. For instance, a complex developablesurface may be a combination of at least a planar and at least a concavesurface, or at least a planar and at least a convex surface, or at leasta concave and at least a convex surface.

In some embodiments, a complex developable surface may also be formed bya combination of planar, conical, cylindrical, and other developablesurfaces and involve both inward and outward bending. In someembodiments, the combination of planar, conical, cylindrical, and otherdevelopable surfaces may be in such a way that no sharp edges form whilegoing from one developable surface to another.

In some embodiments, a complex developable surface or a complexdevelopable surface may include one or more planar portions, one or moreconical portions, one or more cylindrical portions, and/or one or moreother developable surface portions.

In some embodiments, glass substrate is cold-formed into a complexdevelopable surface. A force holding the glass substrate in the complexdevelopable surface is applied and maintained across different portionsof the complex developable surface while the cold-formed glass is bondedto a non-planar rigid support structure at a plurality of non-planarpoints until the bonding is sufficient to maintain the complexdevelopable surface. For example, in the embodiment of FIGS. 1-5 ,injection mold die 110 may be maintained in the position shown in FIG. 3until the material of non-planar rigid support structure 130 issufficiently solidified and bonded to glass substrate 120 to maintainthe cold formed shape of glass substrate 120 in the absence injectionmold die 110. Similarly, in the embodiment of FIGS. 8-10 ,direct-bonding die 810 may be maintained in the position shown in FIG. 9until the adhesive layer 831 is sufficiently cured, and glass substrate820 is sufficiently bonded to rigid support structure 830 to maintainthe cold formed shape of glass substrate 820 in the absence directbonding die 810.

Force may be “maintained” in an area by application of force in spacedor periodic parts of the area. For example, direct bonding die 810 maycontact glass substrate 820 everywhere except where rigid supportstructure 830 is present, as shown in FIG. 9 . Or, there may be gaps insuch contact, where contact is maintained at enough points to hold glasssubstrate 820 in place until adhesive layer 830 can cure.

If force is not applied and maintained across different regions of acomplex developable surface, complications may arise. For example, if,instead of using a die process or other process that applies andmaintains force, a single roller is used, it may be difficult to bond aglass substrate to a rigid support structure having a complexdevelopable surface. At the very least, yield is expected to suffer.Without being bound by theory, internal stress exists in cold-formedglass. In the absence of external constraints, this stress will move theglass towards its initial shape.

For example, as shown in FIG. 17 , a single roller 1790 is used to pressan initially planar glass substrate 1720 against a rigid supportstructure 1730 having a complex developable surface—three adjacentcylindrical surfaces, where the middle surface has a concavity oppositethe outer two. An adhesive layer 1731 is present on rigid supportstructure 1730. As roller 1790 passes from left to right, stresses inthe cold-formed glass substrate 1720 to the left of roller 1790 willtend to return glass substrate 1720 to a planar shape, as illustrated byarrows 1780. These stresses may lead to delamination, or low yield. Forsimple shapes, this phenomena may not be present (for example in aplane), or may be addressed in other ways (for example, when adheringglass with adhesive to the inside of a cylinder, a slight compressiveforce across the plane of the glass may push the glass against theadhesive everywhere as the adhesive cures). But, for complex developablesurfaces, particularly those with different regions having differentconcavity, application and maintenance of force is preferred.

This disclosure describes a process to transform a flat glass substrate(such as the glass substrates described herein), which include theabove-described coatings or surface treatments, into a cold-formed andcurved article supported sufficiently to provide an accurate shape tomatch a curved display. In some embodiments, a die is used to impart adesired shape to a glass substrate by cold-forming the glass substrateinto the desired shape. The die is also used to bond a non-planar rigidsupport structure to the cold-formed substrate while the die isimparting the desired shape. Once the non-planar rigid support structureis bonded to the cold-formed glass substrate, the die may be removed,and the non-planar rigid support structure maintains the desired shapeof the cold-formed glass substrate. A die may be reused many times toreproducibly and precisely create the same shape for multiple articlescomprising a non-planar rigid support structure bonded to a cold-formedglass substrate.

In some embodiments, an injection molding process is used to transformthe flat glass substrate described herein to cold-formed and curvedarticle created by injection molding a support structure on a majorsurface of the glass substrate, thus providing a superior supportstructure to hold the glass substrate to the prescribed shape and havingthe flexibility to match the curved display.

In some embodiments, a direct bonding process is used to cold-form andbond a previously flat glass substrate to a curved support structure,using that curved support structure to provide rigidity to the glasssubstrate and to hold the glass substrate into a cold-form shape of thecurved support structure.

Either injection molding or direct bonding could provide support over asignificant portion of the major surface of the glass substrate tosupport and maintain the cold-form shape, while minimizing the stressesimparted on the glass substrate.

This disclosure also describes an article that is a cold-formed glasssubstrate that is supported by a support structure to maintain a curvedshape and minimize the stresses, and is open (unsupported) for thedisplay area allowing the glass substrate surface to conform to thedisplay shape.

The methods described herein and the resulting articles exhibit highquality and enable the integration of optical and other features.

With respect to high quality, the articles described herein enablesuperior fit to curved displays and exhibit high optical quality. Thinglass substrates may possess a flexible characteristic able toaccommodate the curved display. Cold-forming maintains the high qualityof the flat glass substrate that could be diminished in a thermalforming process. This concept also allows excellent stress management,minimizing the cold-form stress by providing support over a large area.

The articles described herein can easily integrate high quality coatingsand surface treatments on a curved substrate surface, where suchcoatings are typically limited to flat parts. The coatings and/orsurface treatments may be applied to a glass substrate prior tocold-forming, and cold-forming the coated and/or treated glass substratein turn avoids the issues associated with thermal forming (i.e., damageto the coating and/or surface treatment from handling and/or highprocessing temperature).

In some embodiments described herein, the use of a “die” is described.As used herein, a die includes a structure used to impart a desiredshape to a glass substrate, and to attach a non-planar rigid supportstructure to the glass substrate. The die itself is not a part of thefinished article, but rather may be used repeatedly to create manyfinished articles. In one or more embodiments, the term “die” refers toa tool used to impart a desired shape upon an object. In suchembodiments, “die” has at least two parts, a first part and a secondpart, that may be pressed together to impart a desired shape on aflexible object disposed between the first and second parts.

In some embodiments, a non-planar rigid support structure does not coverthe glass substrate where the curved displays will be laminated. Theseareas and the area immediately adjacent do not have the rigid structurebonded to the glass substrate allowing some compliance to accuratelymatch the curved surface of the curved display being laminated to thecover glass assembly.

In some embodiments, direct bonding is used to attach a cold-formedglass substrate to a non-planar rigid support structure.

The non-planar rigid support structure injection molded to the backsideof the glass substrate provides a support structure across the glasssubstrate, leaving exposed the area of the curved display, insuring thenon-display areas of the glass substrate are at the design shape. Thedisplay area of the glass substrate being open allows some compliance tomatch the attached curved display. So, the glass substrate is suitablefor use as a cover glass for a display.

Various techniques other than injection molding may be used to achieve anon-planar rigid support structure attached to a cold-formed glasssubstrate to maintain the cold-formed shape and minimize stresses bysupporting the curved surface over the area of the part excluding thedisplay area.

The Figures are not necessarily drawn to scale. The different parts ofvarious figures may have some parts not drawn to scale relative to otherparts in order to better illustrate concepts.

In some embodiments, injection molding is used to form a non-planarrigid support structure bonded to a surface of a cold-formed glasssubstrate. Any suitable injection molding process and material(s) may beused. For example, polyvinyl chloride (PVC) and thermoplasticpolyurethane (TPU) are two common materials used to injection mold thenon-planar rigid support structure. Reaction injection molding (RIM) maybe used in some embodiments. Common materials used in RIM includepolyurethane polyureas, polyisocyanurates, polyesters, polyphenols,polyepoxides, and nylon 6. Different materials may have differentoperating parameters. The machines, operating parameters (e.g.,pressure, flow rate, temperature), and mold design may be different fordifferent materials. Typical injection molding temperatures range from300° F. to 450° F., and typical process pressures can range from the 200psi to higher than 1000 psi. But, any suitable process parameters may beused.

FIG. 1 illustrates an injection mold die 110 designed with a specificdesired curved shape, and a flat glass substrate 120 with opposing majorsurfaces 121 and 122. Injection mold die 110 includes two parts, a firstdie part 111 and a second die part 112. First and second die parts 111and 112 have a curved shape corresponding to that desired for acold-formed glass substrate. First die part 111 includes recesses 113adapted to receive molten material as a part of an injection-moldingprocess. Flat glass substrate 120 is disposed between first and seconddie parts 111 and 112, but is not yet cold-formed.

FIG. 2 illustrates the die 110 of FIG. 1 cold-forming glass substrate120 into a non-planar shape. The cold-forming is accomplished bypressing together first and second die parts 111 and 112 while glasssubstrate 120 is disposed in between. In FIG. 2 , recesses 113 remainempty.

FIG. 3 illustrates the die of FIG. 2 after material has beeninjection-molded into recesses 113 to form a non-planar rigid supportstructure 130 bonded to the back of the cold-formed glass substrate 120.

FIG. 4 illustrates the die of FIG. 3 and the resultant article afterfirst and second die parts 111 and 112 retract. The resultant article isa cold-formed glass substrate 120 bonded to a non-planar rigid supportstructure 130. Cold-formed glass substrate 120 retains the curvatureimparted by first and second die parts 111 and 112 because of therigidity of non-planar rigid support structure 130. Each of the opposingmajor surfaces (first major surface 121 and second major surface 122)are in tension or compression depending on the direction of curvature.In FIG. 4 , first major surface 121 at a first position 121A that isadjacent the non-planar rigid support structure 130 is in tension whilethe second major surface 122 at a second position 122A adjacent thenon-planar rigid support structure 130 is in compression. Accordingly,the second major surface 122 at a second position 122A exhibits agreater surface compressive stress than the first major surface 121 at afirst position 121A. This is exhibited even when substrate 120 isstrengthened as described herein and exhibits a surface compressivestress prior to being cold-formed.

FIG. 5 illustrates cold-formed glass substrate 120 bonded to non-planarrigid support structure 130 of FIG. 4 , with additional adhesive 140added along the interface where cold-formed glass substrate 120 isbonded to non-planar rigid support structure 130. Additional adhesive140 is optional, and may help improve bonding between cold-formed glasssubstrate 120 and non-planar rigid support structure 130. Althoughadditional adhesive 140 may be applied without using a mold, the overallstructure still benefits from the precision obtained by using a mold tobond cold-formed glass substrate 120 to non-planar rigid supportstructure 130.

FIG. 6 illustrates a perspective view of cold-formed glass substrate 120bonded to a non-planar rigid support structure 130.

FIG. 7 illustrates a top view of a cold-formed glass substrate 120bonded to a non-planar rigid support structure 130. The curvature is notvisible due to the angle of the view. Line 7-7′ shows a cross sectionillustrated by FIGS. 1-5 . FIGS. 8-11 illustrate a similar crosssection.

FIG. 8 illustrates a direct-bonding die 810 designed with a specificdesired curved shape, and a flat glass substrate 820. Direct-bonding die810 includes two parts, a first die part 811 and a second die part 812.First and second die parts 811 and 812 have a curved shape correspondingto that desired for a cold-formed glass substrate. First die part 811includes recesses 813 adapted to receive a non-planar rigid supportstructure 830 formed by a separate process. Non-planar rigid supportstructure 830 may be formed by any suitable process, such as injectionmolding. Non-planar rigid support structure 830 has been inserted intorecesses 831 in first die part 811. Optionally, adhesive layer 831 maybe applied to non-planar rigid support structure 830 by any suitableprocess, before or after non-planar rigid support structure 830 isinserted into recesses 831. Flat glass substrate 820 is disposed betweenfirst and second die parts 811 and 812, but is not yet cold-formed.

FIG. 9 illustrates die 810 of FIG. 8 cold-forming glass substrate 820into a non-planar shape and bonding the non-planar rigid supportstructure to the cold-formed glass substrate. The cold-forming isaccomplished by pressing together first and second die parts 811 and 812while glass substrate 820 is disposed in between. This pressing togetherof first and second die parts 811 and 812 also brings non-planar rigidsupport structure 830 into contact with glass substrate 820, anddirect-bonds non-planar rigid support structure 830 to glass substrate820. Recesses 813 ensure precise positioning of non-planar rigid supportstructure 830 relative to glass substrate 820.

FIG. 10 illustrates die 810 of FIG. 9 and the resultant article afterdie 810 retracts. The resultant article is a cold-formed glass substrate820 bonded to non-planar rigid support structure 820. Optionally,adhesive layer 831 may assist with such bonding. Cold-formed glasssubstrate 820 retains the curvature imparted by first and second dieparts 811 and 812 because of the rigidity of non-planar rigid supportstructure 830.

FIG. 11 illustrates cold-formed glass substrate 820 bonded to non-planarrigid support structure 830 of FIG. 10 , with additional adhesive 840added along the interface where cold-formed glass substrate 820 isbonded to non-planar rigid support structure 830. Additional adhesive840 is optional, and may help improve bonding between cold-formed glasssubstrate 820 and non-planar rigid support structure 830. Althoughadditional adhesive 840 may be applied without using a mold, the overallstructure still benefits from the precision obtained by using a mold tobond cold-formed glass substrate 820 to non-planar rigid supportstructure 830.

FIG. 12 shows a process flowchart corresponding to the processillustrated in FIGS. 1 to 5 . The following steps are performed, inorder:

Step 1210—Die 110 is used to cold-form glass substrate 120 into adesired shape.

Step 1220—Rigid support structure 130 is formed in recesses 113 andbonded to cold-formed glass substrate 120 by injection molding.

Step 1230—Die 110 is removed.

Step 1240—Optionally, additional adhesive 140 is applied.

FIG. 13 shows a process flowchart corresponding to the processillustrated in FIGS. 8 to 10 . The following steps are performed, inorder:

Step 1310—Rigid support structure 830 is placed in recesses 813.

Step 1320—Die 810 is used to cold-form glass substrate 820 into adesired shape while direct bonding rigid support structure 830 tocold-formed glass substrate 820.

Step 1330—Die 810 is removed.

Step 1340—Optionally, additional adhesive 840 is applied.

FIG. 14 illustrates a die 1410 having first die part 1411 and second diepart 1412. First die part 1413 includes recesses 1413. As illustrated,both first die part 1411 and second die part 1412 include ridges 1414useful for precisely positioning glass substrate 1420 relative to firstand second die parts 1411 and 1412. This allows a rigid supportstructure to be precisely placed relative to glass substrate 1420,whether by injection molding, direct bonding, or other die-basedprocess. In some embodiments, ridges may be present on only one of firstdie part 1411 and second die part 1412. In some embodiments, ridges 1414may be absent.

FIG. 15 shows an example of a part, a section of an automotive interiordisplay, including but not limited to an instrument cluster, a consoledisplay, or a center stack display, having a monitor, that may be madein some embodiments. A cold-formed glass substrate is bonded to a rigidsupport structure 1530. Cold-formed glass substrate 1510 includes anopen region 1550 that is not in direct contact with non-planar rigidsupport structure 1530. Open region 1550 has a curved shape maintainedby the non-planar rigid support structure 1530. A monitor or display maybe laminated to open region 1550. Rigid support structure 1530 may bedesigned to be attached to other parts of an automobile (such as adashboard, center console, instrument panel, seat back, seat front,floor board, door panel, pillar, arm rest etc.) or an architecturalapplication (such as a wall, window, wall panel, furniture, appliance,door, etc.). The embodiment of FIG. 15 may be formed by any of variousprocesses disclosed herein, including the embodiment of FIG. 12 and theembodiment of FIG. 13 .

FIG. 16 illustrates a top view of a cold-formed glass substrate 120bonded to a non-planar rigid support structure 130. The curvature is notvisible due to the angle of the view. The interior of non-planar rigidsupport structure 130 defines an open region 1610 of the cold-formedglass substrate that is not in direct contact with the non-planar rigidsupport structure. Open region 1610 has a curved shape maintained by thenon-planar rigid support structure. Display 1620 is attached tocold-formed glass substrate 120. Display 1620 is visible through openregion 1610 of cold-formed glass substrate 120.

One or more embodiments pertain to a vehicle interior system thatincludes a base including a non-planar support structure, and acold-formed glass substrate (or laminate including a cold-formedsubstrate, as described herein) disposed on the non-planar supportstructure. In one or more embodiments, the base includes a displaydisposed between the base and the cold-formed substrate (or laminateincluding a cold-formed substrate). The display may be curved. In one ormore embodiments, a cold-formed glass substrate comprises a thickness of1.5 mm or less (or from about 0.4 mm to about 1.3 mm).

In one or more embodiments, the cold-formed glass substrate used in suchvehicle interior systems comprises a glass surface, and wherein at allpoint of the glass surface have a Gaussian curvature (GC) that is equalto zero (GC=Kmax*Kmin, wherein Kmax and Kmin are principal curvaturesdefined as Kmax=1/R′ and Kmin=1/R″), and wherein one of Kmax and Kmin isnon-zero, R′ is the maximum radius of curvature and R″ is the minimumradius of curvature.

In one or more embodiments, the cold-formed glass substrate (or laminateincluding a cold-formed substrate, as described herein) used in suchvehicle interior systems includes a portion of a surface that comprisesa concave shape and an R′ of the concave shape is in a range from about37.5 mm to about 500 mm. In some embodiments with a convex surface, thethickness of the substrate may be 0.4 mm and the R′ may be in a rangefrom about 100 mm to about 200 mm, from about 125 mm to about 200 mm,from about 150 mm to about 200 mm, form about 175 mm to about 200 mm,from about 100 mm to about 175 mm, from about 100 mm to about 150 mm, orfrom about 100 mm to about 125 mm. In some embodiments with a convexsurface, the thickness of the substrate may be 0.55 mm and the R′ may bein a range from about 150 mm to about 250 mm, from about 175 mm to about250 mm, from about 200 mm to about 250 mm, form about 225 mm to about250 mm, from about 150 mm to about 225 mm, from about 150 mm to about200 mm, or from about 150 mm to about 175 mm. In some embodiments with aconvex surface, the thickness of the substrate may be 0.7 mm and the R′may be in a range from about 200 mm to about 300 mm, from about 225 mmto about 300 mm, from about 250 mm to about 300 mm, form about 275 mm toabout 300 mm, from about 200 mm to about 275 mm, from about 200 mm toabout 250 mm, or from about 200 mm to about 225 mm. In some embodimentswith a convex surface, the thickness of the substrate may be 1.1 mm andthe R′ may be in a range from about 350 mm to about 450 mm, from about375 mm to about 450 mm, from about 300 mm to about 450 mm, form about325 mm to about 450 mm, from about 350 mm to about 425 mm, from about350 mm to about 400 mm, or from about 350 mm to about 375 mm. In someembodiments with a convex surface, the thickness of the substrate may be1.3 mm and the R′ may be in a range from about 450 mm to about 550 mm,from about 475 mm to about 550 mm, from about 400 mm to about 550 mm,form about 425 mm to about 550 mm, from about 450 mm to about 525 mm,from about 450 mm to about 500 mm, or from about 450 mm to about 475 mm.

In one or more embodiments, a portion of a surface that comprises aconvex shape and an R′ (maximum radius of curvature) of the convex shapeis in a range from about 20 mm to about 500 mm. In some embodiments witha concave surface, the thickness of the substrate may be 0.4 mm and theR′ may be in a range from about 15 mm to about 100 mm, from about 30 mmto about 100 mm, from about 50 mm to about 100 mm, form about 75 mm toabout 100 mm, from about 15 mm to about 75 mm, from about 15 mm to about50 mm, or from about 15 mm to about 30 mm. In some embodiments with aconcave surface, the thickness of the substrate may be 0.55 mm and theR′ may be in a range from about 20 mm to about 150 mm, from about 40 mmto about 150 mm, from about 50 mm to about 150 mm, form about 75 mm toabout 150 mm, from about 20 mm to about 125 mm, from about 20 mm toabout 100 mm, or from about 20 mm to about 75 mm. In some embodimentswith a concave surface, the thickness of the substrate may be 0.7 mm andthe R′ may be in a range from about 25 mm to about 175 mm, from about 50mm to about 175 mm, from about 75 mm to about 175 mm, form about 100 mmto about 175 mm, from about 150 mm to about 175 mm, from about 25 mm toabout 150 mm, from about 25 mm to about 125 mm, from about 25 mm toabout 100 mm or from about 25 mm to about 75 mm. In some embodimentswith a concave surface, the thickness of the substrate may be 1.1 mm andthe R′ may be in a range from about 40 mm to about 225 mm, from about 50mm to about 225 mm, from about 75 mm to about 225 mm, form about 100 mmto about 225 mm, from about 150 mm to about 225 mm, from about 40 mm toabout 200 mm, from about 40 mm to about 175 mm, from about 40 mm toabout 150 mm or from about 40 mm to about 100 mm. In some embodimentswith a concave surface, the thickness of the substrate may be 1.3 mm andthe R′ may be in a range from about 150 mm to about 250 mm, from about175 mm to about 250 mm, from about 200 mm to about 250 mm, form about225 mm to about 250 mm, from about 150 mm to about 225 mm, from about150 mm to about 200 mm, or from about 150 mm to about 175 mm.

In one or more embodiments, the base comprises any one of a centerconsole, a dashboard, an arm rest, a pillar, a seat back, a floor board,a headrest, a door panel, and a steering wheel. The vehicle may be anyone of an automobile, a seacraft, and an aircraft.

Embodiments of the present disclosure are described in detail hereinwith reference to embodiments thereof as illustrated in the accompanyingdrawings, in which like reference numerals are used to indicateidentical or functionally similar elements. References to “oneembodiment,” “an embodiment,” “some embodiments,” “in certainembodiments,” etc., indicate that the embodiment described may include aparticular feature, structure, or characteristic, but every embodimentmay not necessarily include the particular feature, structure, orcharacteristic. Moreover, such phrases are not necessarily referring tothe same embodiment. Further, when a particular feature, structure, orcharacteristic is described in connection with an embodiment, it issubmitted that it is within the knowledge of one skilled in the art toaffect such feature, structure, or characteristic in connection withother embodiments whether or not explicitly described.

As used herein, “comprising” is an open-ended transitional phrase. Alist of elements following the transitional phrase “comprising” is anon-exclusive list, such that elements in addition to those specificallyrecited in the list may also be present.

The following examples are illustrative, but not limiting, of thepresent disclosure. Other suitable modifications and adaptations of thevariety of conditions and parameters normally encountered in the field,and which would be apparent to those skilled in the art, are within thespirit and scope of the disclosure.

Aspect (1) of this disclosure pertains to a process comprising:cold-forming a flat glass substrate into a non-planar shape using a die;and bonding the cold-formed glass substrate to a non-planar rigidsupport structure at a plurality of non-planar points using the die.

Aspect (2) of this disclosure pertains to the process of Aspect (1),wherein the die is an injection-molding die, and the bonding isaccomplished by injection molding the non-planar rigid support structureonto the cold-formed glass substrate while the die holds the cold-formedglass substrate in the non-planar shape.

Aspect (3) of this disclosure pertains to the process of Aspect (1),wherein the non-planar rigid support structure is formed prior to thebonding, and the bonding comprises using the die to directly bond thecold-formed glass substrate onto the non-planar rigid support structure.

Aspect (4) of this disclosure pertains to the process of Aspect (3),further comprising placing the non-planar rigid support structure into arecess in the die prior to bonding.

Aspect (5) of this disclosure pertains to the process of Aspect (3) orAspect (4), further comprising applying an adhesive to at least one ofthe non-planar rigid support structure and the flat glass substrateprior to bonding.

Aspect (6) of this disclosure pertains to the process of any one ofAspects (1) through (5), further comprising, after bonding, applying anadhesive to an edge of an interface between the cold-formed glasssubstrate and the non-planar rigid support structure.

Aspect (7) of this disclosure pertains to the process of any one ofAspects (1) through (6), further comprising applying a coating to theflat glass substrate prior to cold-forming.

Aspect (8) of this disclosure pertains to the process of Aspect (7),wherein the coating is an ink coating.

Aspect (9) of this disclosure pertains to the process of Aspect (7),wherein the coating is an antireflective coating.

Aspect (10) of this disclosure pertains to the process of any one ofAspects (7) through (9), wherein the cold-formed glass substrate, afterbonding to the non-planar rigid support structure, includes an openregion not in direct contact with the non-planar rigid supportstructure, the open region having a curved shape maintained by thenon-planar rigid support structure.

Aspect (11) of this disclosure pertains to the process of Aspect (10),further comprising attaching a display to at least one of the coldformed glass substrate and the non-planar rigid support structure, suchthat the display is visible through the open region of the cold-formedglass substrate.

Aspect (12) of this disclosure pertains to the process of any one ofAspects (1) through (11), wherein, during and after cold-forming, thetemperature of the glass substrate does not exceed 800° F.

Aspect (13) of this disclosure pertains to the process of any one ofAspects (1) through (12), wherein the glass substrate comprises astrengthened glass.

Aspect (14) of this disclosure pertains to the process of any one ofAspects (1) through (13), wherein the cold-formed glass substrate hasopposing major surfaces, and wherein one major surface is free of thenon-planar rigid support structure.

Aspect (15) pertains to an article comprising: a cold-formed glasssubstrate comprising a non-planar shape and a first major surface and anopposing second major surface, the first and second major surfacescomprising a surface compressive stress that differ from one another; anon-planar rigid support structure bonded to the first major surface ata plurality of non-planar points.

Aspect (16) pertains to the article of Aspect (15), wherein: thenon-planar rigid support structure is injection molded onto thecold-formed glass substrate while the cold-formed glass comprises thenon-planar shape.

Aspect (17) pertains to the article of Aspect (15), wherein thecold-formed glass substrate comprises a second major surface oppositethe first major surface, the second major surface comprising a coatingor surface treatment.

Aspect (18) of this disclosure pertains to the process of any one ofAspects (15) through (17), further comprising an edge adhesive appliedto an edge of an interface between the cold-formed glass substrate andthe non-planar rigid support structure.

Aspect (19) of this disclosure pertains to the process of any one ofAspects (15) through (18), wherein the cold-formed glass substrateincludes an open region not in direct contact with the non-planar rigidsupport structure, and the open region has a curved shape maintained bythe non-planar rigid support structure.

Aspect (20) pertains to the article of Aspect (19), further comprising adisplay attached to at least one of the cold formed glass substrate andthe non-planar rigid support structure, wherein the display is visiblethrough the cold-formed glass substrate.

Aspect (21) of this disclosure pertains to the process of any one ofAspects (15) through (20), further comprising a coating disposed on thecold-formed glass substrate.

Aspect (22) of this disclosure pertains to the process of Aspect (21),wherein the coating is an ink coating.

Aspect (23) of this disclosure pertains to the process of Aspect (21),wherein the coating is an antireflective coating.

Aspect (24) of this disclosure pertains to an article comprising: aglass substrate having opposing major surfaces and a curved shape, theopposing major surfaces comprising a surface stress that differ from oneanother, wherein the glass substrate is attached to a rigid supportstructure having the curved shape, wherein the glass substrate includesan open region not in direct contact with the non-planar rigid supportstructure, and the open region has a curved shape maintained by thenon-planar rigid support structure.

Aspect (25) of this disclosure pertains to an article comprising: anon-planar rigid support structure having a complex developable surface;a cold-formed glass substrate bonded to the non-planar rigid supportstructure, the cold formed glass substrate having the complexdevelopable surface.

Aspect (26) of this disclosure pertains to the article of Aspect (25) orAspect (24), further comprising a display attached to at least one ofthe glass substrate and the non-planar rigid support structure, whereinthe display is visible through the open region of the glass substrate.

Aspect (27) of this disclosure pertains to an article of any one ofAspects (24) through (26), further comprising a coating disposed on theglass substrate.

Aspect (28) of this disclosure pertains to an article of Aspect (27),wherein the coating is an ink coating.

Aspect (29) of this disclosure pertains to an article of Aspect (27),wherein the coating is an antireflective coating.

Aspect (30) of this disclosure pertains to an article of any one ofAspects (24) through (29), wherein the glass substrate is a chemicallystrengthened glass substrate.

Aspect (31) of this disclosure pertains to an article of any one ofAspects (24) through (30), wherein one major surface is free of thenon-planar rigid support structure.

Aspect (32) of this disclosure pertains to an article of any one ofAspects (24) through (31), wherein the cold formed glass substrate has acomplex developable surface.

Aspect (33) of this disclosure pertains to vehicle interior systemcomprising: a base having a curved surface; an article comprising acold-formed glass substrate disposed on the curved surface, wherein theglass substrate comprises a surface, and wherein at all point of thesurface have a Gaussian curvature (GC) that is equal to zero(GC=Kmax*Kmin, wherein Kmax and Kmin are principal curvatures defined asKmax=1/R′ and Kmin=1/R″), and wherein one of Kmax and Kmin is non-zero,R′ is the maximum radius of curvature and R″ is the minimum radius ofcurvature.

Aspect (34) pertains to the vehicle interior system of Aspect (33),wherein the glass substrate has a thickness of about 1.5 mm or less.

Aspect (35) pertains to the vehicle interior system of Aspect (33) orAspect (34), wherein a portion of the surface comprises a concave shapeand R′ of the concave shape is in a range from about 37.5 mm to about500 mm.

Aspect (36) pertains to the vehicle interior system of Aspect (33) orAspect (34), wherein a portion of the surface comprises a convex shapeand R′ of the convex shape is in a range from about 20 mm to about 500mm.

Aspect (37) pertains to the vehicle interior system of any one ofAspects (33) through (36), further comprising a display.

Aspect (38) pertains to the vehicle interior system of Aspect (37),wherein the display is disposed between the base and the article.

Aspect (39) pertains to the vehicle interior system of Aspect (37) orAspect (38), wherein the display is curved.

Aspect (40) pertains to the vehicle interior system of any one ofAspects (33) through (39), wherein the glass substrate is strengthened.

While various embodiments have been described herein, they have beenpresented by way of example only, and not limitation. It should beapparent that adaptations and modifications are intended to be withinthe meaning and range of equivalents of the disclosed embodiments, basedon the teaching and guidance presented herein. It therefore will beapparent to one skilled in the art that various changes in form anddetail can be made to the embodiments disclosed herein without departingfrom the spirit and scope of the present disclosure. The elements of theembodiments presented herein are not necessarily mutually exclusive, butmay be interchanged to meet various needs as would be appreciated by oneof skill in the art.

Embodiments described herein may be combined in any permutation.

It is to be understood that the phraseology or terminology used hereinis for the purpose of description and not of limitation. The breadth andscope of the present disclosure should not be limited by any of theabove-described exemplary embodiments, but should be defined only inaccordance with the following claims and their equivalents.

What is claimed is:
 1. An article comprising: a cold-formed glasssubstrate comprising a first major surface, a second major surfaceopposite the first major surface, a thickness extending between thefirst major surface and the second major surface that is greater than orequal to 0.4 mm and less than or equal to 1.3 mm, and a non-planarshape; a non-planar rigid support structure bonded to the glasssubstrate and configured to retain the cold-formed glass substrate inthe non-planar shape, wherein: the non-planar rigid support is bonded tothe first major surface of the cold-formed glass substrate such that thenon-planar rigid support retains the cold-formed glass substrate in thenon-planar shape despite the first major surface and the second majorsurface comprising different surface stresses from bending, thecold-formed glass substrate is the only glass substrate in the article,the cold-formed glass substrate consists of a single sheet of chemicallystrengthened glass that optionally includes one or more coatings orsurface treatments, and the non-planar rigid support structure is acomponent of a base of an automobile interior, wherein the base of theautomobile interior comprises a dashboard, a center console, aninstrument panel, a seat back, a seat front, a floor board, a doorpanel, a pillar, or an arm rest.
 2. The article of claim 1, wherein,when viewed from the second major surface, the cold-formed glasssubstrate completely covers the non-planar rigid support.
 3. The articleof claim 2, further comprising a decorative ink coating on at least oneof the first major surface and the second major surface.
 4. The articleof claim 1, wherein the non-planar shape comprises a curved shape suchthat at least one of the first major surface and the second majorsurfaces comprises a concave or a convex shape.
 5. The article of claim4, wherein the concave or the convex shape comprises a radius ofcurvature that is greater than or equal to 20 mm and less than or equalto 500 mm.
 6. The article of claim 1, wherein the cold-formed glasssubstrate comprises a Gaussian curvature that is equal to zero.
 7. Thearticle of claim 1, wherein the non-planar rigid support structure isbonded to the first major surface at one or more non-planar points onthe first major surface that are offset from a minor surface of thecold-formed glass substrate extending between the first major surfaceand the second major surface.
 8. The article of claim 1, wherein thenon-planar rigid support structure is formed on and bonded to the firstmajor surface by injection molding without the use of adhesive.
 9. Thearticle of claim 1, wherein an outer edge of the non-planar rigidsupport structure is disposed inward of a minor surface of thecold-formed glass substrate extending between the first major surfaceand the second major surface.
 10. An article comprising: a cold-formedglass substrate comprising a first major surface, a second major surfaceopposite the first major surface, and a non-planar shape; a non-planarrigid support structure bonded to the first major surface of the glasssubstrate such that the non-planar rigid support structure retains thecold-formed glass substrate in a non-planar shape when the cold-formedglass substrate has an asymmetrical surface compressive stressdistribution, wherein: the cold-formed glass substrate is the only sheetof glass in the article, and the non-planar rigid support structure isformed on and bonded to the first major surface by injection moldingwithout the use of an adhesive, the non-planar shape comprises a curvedshape such that at least one of the first major surface and the secondmajor surfaces comprises a concave or a convex shape, the concave or theconvex shape comprises a radius of curvature that is greater than orequal to 20 mm and less than or equal to 500 mm, and the cold-formedglass substrate comprises a thickness that is greater than or equal to0.4 mm and less than or equal to 1.3 mm.
 11. The article of claim 10,wherein: the cold formed glass substrate comprises a minor surfaceextending between the first major surface and the second major surface,and an edge interface on the minor surface is free of adhesive.
 12. Thearticle of claim 10, wherein an entirety of a contact area between thenon-planar rigid support structure and the cold-formed glass substrateis on the first major surface.
 13. The article of claim 10, wherein thenon-planar rigid support structure is configured to be attached to acomponent of an automobile interior.
 14. The article of claim 13,wherein the component comprises a display, a dashboard, a centerconsole, an instrument panel, a seat back, a seat front, a floor board,a door panel, a pillar, or an arm rest.
 15. The article of claim 10,wherin, when viewed from the second major surface, the cold-formed glasssubstrate completely covers the non-planar rigid support.
 16. Thearticle of claim 15, further comprising a decorative ink coating on atleast one of the first major surface and the second major surface. 17.The article of claim 10, wherein an outer edge of the non-planar rigidsupport structure is disposed inward of a minor surface of thecold-formed glass substrate extending between the first major surfaceand the second major surface.
 18. The article of claim 10, wherein thecold-formed glass substrate comprises a surface compressive stress ofgreater than or equal to 300 MPa at the first major surface or thesecond major surface.
 19. The article of claim 10, wherein the thenon-planar rigid support structure is bonded to the first major surfaceat one or more non-planar points on the first major surface that areoffset from a minor surface of the cold-formed glass substrate extendingbetween the first major surface and the second major surface.